Shelving brace

ABSTRACT

A rectangular shelf is supported along its sides by opposing deck beams and supported on its ends by opposing end frame members, all joined to corner posts. A hook on each opposing end of a cross-brace engages a different latch affixed to each deck beam to keep the deck beams from splaying under heavy load. The latches are formed from a threaded nut or a washer having a flat side that is affixed to the deck beam by heat or an adhesive.

CROSS-REFERENCE TO RELATED APPLICATIONS

The application claims the benefit under 35 U.S.C. §119(e) to Provisional Patent Application No. 62/041,404 filed Aug. 25, 2014, the entire contents of which are incorporated herein by reference.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND

Shelves typically include four corner posts in a rectangular arrangement with deck beams extending along the long sides of the shelves and fastened to different pairs of four corner posts to form a support for each shelf. Shelving units may have several such shelves and may have end frame members extending between posts to cooperate with the deck beams to form a rectangular support for the shelves. In order to keep the shelving units light the deck beams and end frame members are often formed with an open section and typically have a flange or shoulder extending from a vertical web of the deck beam or end frame member, with the shelf resting on the shoulder or flange. The flange or shoulder extends along the length of the deck beam and end frame members.

As the loads placed on the shelves increase the force on the shoulders or flanges begins to twist the deck beams. To better accommodate higher loading on the shelves, the deck beams may be made with a closed sections or made of thicker material. But both of those approaches increase the weight of the deck beams and increase the cost. There is thus a need for a deck brace that is light weight but can accommodate high loads on the shelves.

Cross-braces are sometimes used to support the shelves and increase the load carrying capability. Cross-braces typically extend between the shoulders or flanges that support the shelf and help keep the shoulder and flanges from bending and twisting the deck beams as well as supporting the bottom of the shelves. But that approach requires a connection with the shoulder that does not interfere with the shelf, thus complicating manufacturing and assembly.

Some cross-braces bolt to opposing sides of the deck beams. But forming the holes and fasteners for the cross-braces requires multiple manufacturing steps and multiple assembly steps, both of which can increase cost and reduce ease of assembly. There is thus a need for a cross-brace that is inexpensive to manufacture and easy to assemble.

BRIEF SUMMARY

A rectangular shelf is supported along its sides by opposing deck beams and supported on its ends by opposing end frame members, all joined to corner posts. A hook on each opposing end of a cross-brace engages a different latch affixed to each deck beam to keep the deck beams from splaying under heavy load. The latches are formed from a threaded nut or a washer having a flat side that is affixed to the deck beam by heat or an adhesive.

There is advantageously provided a shelving unit having a pair of rear posts extending upward and a pair of front posts extending upward with two pairs of elongated front and rear deck beams extending between and releasably connected to respective pairs of rear posts and front posts in the same plane and parallel to each other to define a support for a shelf during use. The shelving unit further includes a first shelf having two opposing first deck beams each having a first shelf support surface extending along a length of the respective first deck beam adjacent an upper side of the respective first deck beam. Each of the first deck beams has a threaded nut or a washer each with a solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of each respective first deck beam to form a first latch located adjacent the lower side of the respective first deck beam. The first latches are orientated relative to the respective first deck beam so an opening through the nut or washer faces upward during use. The first latches are directly opposite each other. The shelving unit has a plurality of second deck beams having a second shelf support surface extending along a length of the respective second deck beam adjacent an upper side of the respective second deck beam. A threaded nut or a washer having solidified metal or an adhesive affixes a flat side of the nut or washer to an inward facing surface of each of the respective second deck beams to form a second latch also located adjacent the lower side of the respective second deck beam. The nut or washer is orientated relative to the respective second deck beam so an opening through the nut or washer faces upward during use. The first and second latches are located at corresponding locations on their respective deck beams so the first and second latches are directly opposite each other. The first shelf also includes a first cross-brace having an elongated body with two opposing ends, each end having a hook extending in the same direction. Each hook fits through the opening in a different one of the first latches to help the first deck beams resist splaying under a heavy load. The shelving unit also includes a second shelf and second cross-brace constructed as the first shelf and first cross-brace, but spaced apart therefrom.

There is also provided a deck beam and cross-brace for use with a support frame for a shelf in a shelving assembly. The shelf assembly includes a pair of rear posts extending upward and an opposed pair of front posts extending upward. Elongated front and rear deck beams extend between and are connected to respective pairs of rear posts and front posts in the same plane and parallel to each other to define a support for a shelf. Each of the deck beams has an upper side and a lower side and at least one shelf support extending from the beam toward an inside of the shelf assembly for supporting the shelf during use.

The deck beam and cross-brace include a first deck beam having a first shelf support surface extending along a length of the first deck beam adjacent an upper side of the first deck beam. A threaded nut or a washer, each having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of first deck beam, forms a first latch. The first latch is located adjacent the lower side of the first deck beam. The nut or washer is orientated relative to the first deck beam so an opening through the nut or washer faces upward during use. A second deck beam has a second shelf support surface extending along a length of the second deck beam adjacent an upper side of the second deck beam. A threaded nut or a washer having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of second deck beam forms a second latch. The second latch is located adjacent the lower side of the first deck beam. The nut or washer is orientated relative to the second deck beam so that an opening through the nut or washer faces upward during use. The first and second latches are located at corresponding locations on their respective deck beams so the first and second latches are directly opposite each other during use. A cross-brace is also provided having an elongated body with two opposing ends. Each end has a hook extending in the same direction during use. Each hook is sized to fit through the opening in one of the first or second latches during use. The cross-brace has a length selected so the each hook can pass through the upward facing opening of a different latch during use when the latches are directly opposite each other. The hooks are configured to pass through the openings during use.

In further variations, melted metal affixes the latch to the deck beam. Further, at least one latch is a threaded nut or a washer with a flat side. Advantageously, at least one latch is a threaded nut and the opening in the nut is elongated with a long axis perpendicular to the deck beam at the location of the latch. The threaded nut may be a square nut, hexagonal nut, a rhombus shaped nut. The first latch is advantageously generally parallel to the first shelf support, as is the second latch. But the first and/or second latches may be inclined at an angle of about 30 degrees or less from an axis perpendicular to the first shelf support. The first and second latches are preferably located at about the center of a length of the respective deck beams when only one cross-brace is used.

Additionally, the cross-brace may be a rod with a circular cross-section, or a braided metal or chain. One end of the cross brace may be smaller in cross-section than the other end to make it easier to insert the smaller end into the mating latch when the other (larger) end is already inserted through its mating latch.

Instead of solidified metal the latches may be affixed to the deck beam using adhesive. The adhesive may be used with threaded nuts, with washers and with the other variations of latches described herein. Instead of threaded nuts, at least one of the first and second latches may be a washer with a flat side. The washer may have an opening that is elongated with a long axis of that opening perpendicular to the deck beam at the location of the at least one latch. When the first latch is a washer it is also generally parallel to the first shelf support and the second latch is generally parallel to the second shelf support. Whether the latches are formed of washers or threaded nuts, it is advantageous if the first latch is inclined at an angle of about 30 or less from an axis perpendicular to the first shelf support.

There is also advantageously provided a kit for a shelving assembly having a pair of rear posts configured to extend upward during use and a pair of front posts configured to extend upward during use, with at least one pair of elongated front and rear deck beams configured to extend between and connected to respective pairs of rear posts and front posts in the same plane and parallel to each other to define a support for a shelf during use. The kit also includes a plurality of first deck beams having a first shelf support surface extending along a length of the respective first deck beam adjacent an upper side of the respective first deck beam, and a threaded nut or a washer having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of respective first deck beam to form a first latch located adjacent the lower side of the respective first deck beam. The nut or washer is orientated relative to the respective first deck beam so an opening through the nut or washer faces toward the shelf support surface.

The kit also includes a plurality of second deck beams having a second shelf support surface extending along a length of the respective second deck beam adjacent an upper side of the respective second deck beam, and a threaded nut or a washer having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of respective second deck beam to form a second latch located adjacent the lower side of the respective second deck beam. The nut or washer is orientated relative to the respective second deck beam so an opening through the nut or washer faces the second shelf support. The first and second latches are located at corresponding locations on their respective deck beams so the first and second latches are directly opposite each other during use when the ends of the beams are connected to the posts.

The kit also includes a plurality of cross-braces each having an elongated body with two opposing ends. Each cross-brace has a hook extending in the same direction during use. Each hook is sized to fit through the opening in one of the first or second, directly opposing latches during use. The cross-braces each having a length selected so the each hook can pass through the upward facing opening of a different latch during use when the latches are directly opposite each other. The hooks are configured to pass through the openings during use.

There is also provided a method of making a latch for a deck beam for use with a shelving unit having opposing deck beams each connected to different pairs of posts to form a support for a rectangular shelf. The latch has an opening extending therethrough which is configured to receive a hook on the end of a cross-brace. The method includes the step of placing one of a washer with a flat side or a threaded nut having a flat side against a side of a deck beam. The deck beam has a shelf support extending along an upper side of the deck beam and configured to support a side of a shelf during use. The deck beam also has one of a connector or a recess at opposing distal ends of the deck beam to releasably connect the deck beam to a post during use. The method further includes positioning the one of the washer or threaded nut adjacent a lower side of the deck beam with a face of the one of the washer or threaded nut facing toward the shelf support. The method further includes applying heat or an adhesive to the one of the washer or threaded nut to affix the one of the washer or threaded nut to the deck beam and form a latch for a cross-brace.

In further variations, the positioning step positions a threaded nut generally parallel to the shelf support and the applying step uses heat to melt at least one of the deck beam and the threaded nut. In further variations, the positioning step positions a washer generally parallel to the shelf support and the applying step uses heat to melt at least one of the deck beam and the threaded nut.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, and other features and advantages of the present invention are further described in the following drawings and description in which like numbers refer to like parts throughout, and in which:

FIG. 1 is a perspective view of a shelving unit having two shelves removed to show a cross-brace;

FIG. 2 is a lower perspective view of a shelf brace connected to a shelf beam of FIG. 1 with a cross-brace;

FIG. 3 is a left side perspective view of the a portion of the shelf beam connected to the cross-brace of FIG. 2 with the shelf removed;

FIG. 4 is an exploded perspective view of the cross-brace and shelf beam of FIG. 3;

FIG. 5 is an alternative embodiment of the cross-brace and shelf beam of FIG. 4;

FIG. 6 is a perspective view of a hook and a square nut for a latch;

FIG. 7 is a perspective view of a hook and a rectangular nut for latch;

FIG. 8 is a perspective view of a hook and rhombus nut for a latch;

FIG. 9 is a perspective view of a hook and a washer having a flat used for a latch;

FIG. 10 is a perspective view of a hook and square washer used for a latch;

FIG. 11 is a perspective view of a hook and D-washer used for a latch;

FIG. 12 is a deck beam with a Z shaped cross-section with a nut for a latch;

FIG. 13 is a deck beam with a step shaped cross-section with a nut for a latch;

FIG. 14 is a deck beam with an inverted L shaped cross-section with a nut for a latch;

FIG. 15 is a deck beam with a C shaped cross-section with a nut for a latch;

FIG. 16 is a perspective view of a portion of the shelving unit of FIG. 1 showing two cross-members;

FIG. 17 is a perspective view of a portion of the shelving unit of FIG. 1 showing three cross-members; and

FIG. 18 is a top view of an annular connector formed so its opening is an oval shape.

DETAILED DESCRIPTION

Referring to FIGS. 1-3, a storage rack 10 includes at least two and preferably at least four vertical supports or posts 12 which are typically vertical or substantially vertical, with a bottom of each post having an optional base configured to rest against a support surface, such as a floor. The base typically has a flat surface that abuts and is parallel to the support surface. The posts 12 are generally arranged at the corners of a rectangle with a front and rear post at each end of the rectangle. The posts 12 may be referred to herein as corner posts.

As used herein the relative directions front and rear are with respect to an aisle along which the storage rack 10 is placed with two, spaced apart front posts adjacent the aisle and two rear posts further away from the aisle. The relative directions of inward and outward refer to the relative direction toward an inside of the storage rack 10 from that aisle. The relative directions up and down, upwards or downwards, or above and below, are with respect to the direction of gravity when the storage rack 10 is in its vertical, use position.

Each of the pair of front posts 12 a, 12 c and rear posts 12 b and 12 d are preferably, but optionally, rigidly interconnected to one another by a plurality of deck beams 14 and end frame members 16. A diagonal brace (not shown) may be optionally provided. The end frame members 16 are located at or adjacent to the top and bottom of the posts 12 a, 12 b and the posts 12 c and 12 d, and preferably offset from the ends so that posts 12 can be bolted end-to-end to increase the length of the post. The depicted end frame members 16 and deck beams are horizontal and aligned with one another to form a planar support for a shelf 18. The depicted posts 12 are shown as angled members having two legs at right angles to each other in cross-section. The cross-sectional shape of the posts 12, frame members 16 and braces 18 will vary with the design strength of the storage rack 10, as will the thickness or gauge of the material used. Posts 12 with C-sections, or square sections may be sued. The posts 12, frame members 16 and the optional diagonal brace may be optionally be bolted together or fastened by any known means. For heavier strength units those parts are preferably of metal and may be welded together to form an end frame assembly. For lighter units the parts are bolted together or are held together by the end frame members 16 and deck members 14. The number, location and shape of end frame members 16, deck beams 14 and any optional diagonal braces may vary.

The posts 12 have a plurality of aligned post openings 22 (FIGS. 1-2). The post openings 22 may be on various sides of the posts and may have various shapes. The depicted post openings 22 are on both sides of the posts 12 a-12 d. The post openings 22 preferably have a tear drop shape known in the art with a generally circular top portion (FIGS. 1 and 2) and a narrower bottom portion so that an enlarged head of a connector attached to an end of end member 16 or deck beam 14 can fit in the larger top portion and be restrained by the smaller bottom portion which receives the smaller sized shaft to which the enlarged connector head is fastened. Exemplary openings 22 are described in U.S. Pat. Nos. 4,074,812 and 5,624,045, the complete contents of which are incorporated herein by reference. The post openings are preferably formed in pairs so two openings 22 are adjacent each other. The post openings 22 are configured to receive connectors 26 on deck beams and end frames. By placing the connectors 26 on opposing pairs of deck beams 14 and end frame members 16 into corresponding sets of openings 22, a level, rectangular support for shelf 18 may be formed.

Extending horizontally between the adjacent posts 12 are the horizontal deck beams 14, with front deck beams 14 a extending between adjacent front posts 12 a, 12 c and rear deck beams 14 b extending between adjacent rear posts 12 b, 12 d. The front and rear deck beams 14 a, 14 b extend between and are supported by each of the front (12 a, 12 c) and rear posts 12 c, 12 d, respectively. A plurality of deck beams extend between the posts 12 at the location of each desired shelf. Five rows of deck beams are shown in FIG. 1 along with five rows of end frame members 16 for a five shelf shelving unit 10. The number of shelves 18 can be varied by adding or removing the supporting deck beams 14 and end frame members 16 and cross-braces 28.

The deck beams 14 have a shaped cross-section which forms a horizontal ledge or shelf support 20 extending inward toward a center of the shelving unit 10 and located below an upper edge or side of the deck beam a distance that is preferably about the same as the thickness of shelf 18. Various open cross-sections for such beams 14 are shown in FIGS. 12-15, and these are known in the art. A bottom flange 24 (FIG. 3) extends along the length of the deck beam at the bottom edge or side of the deck beam 14. The flange 24 is shown as inclined slightly outward at an angle of a few degrees from the vertical portion of the deck beam, but the flange 24 may be inclined inward, or may form a short flange extending perpendicular to the face of beam 14 and preferably extending inward. The bottom flange 24 is a stiffening flange to strengthen the deck beam 14.

The deck beams 14 and end frame members 16 have connectors 26 (FIGS. 1-2) extending from the beams 14 and members 16 and configured to engage the post openings 22. Alternatively, the ends of the deck beams 14 and end frame members 16 could be configured to engage post openings 22, with the openings configured to mate with the configured ends of the beams 14 and members 16.

Referring still to FIGS. 1-3, a cross-brace 28 extends between two opposing and generally parallel deck beams 14 a, 14 b. The cross-brace 28 is preferably an elongated rod or other member having a hooked end 30 configured to engage an annular latch 32 fastened to and extending inward from the deck beam 14. The cross-brace is preferably at least 100 times longer than its largest cross-sectional dimension. The cross-brace 28 helps keep the deck beams 14 from spreading apart or splaying when the load on the shelves becomes large enough to bow or deform the deck beams.

The hooked end 30 is preferably bent or otherwise formed to extend at an acute angle from the longitudinal axis of the cross-brace 28. An acute angle of about 80-89 degrees is believed suitable, and an angle of about 85-89 degrees being more preferably and an angle of about 87-89 degrees being preferred. The angle on the hooked end 30 depends on the opening 34 in the annular latch 32 as the hooked end 30 passes through the opening 34 and preferably passes through vertically.

The latch 32 is preferably formed by the female portion of a threaded fastener which has flat sides that are joined by heat to the deck beam, such as being welded, glued, soldered, ultrasonically welded, frictionally welded, or otherwise fastened to the inner side of the deck beam 14. This melted and solidified material 33 forms a connecting material affixing the latch to the deck beam.

Preferably portion of the deck beam 14 or the latch 32 is melted and more preferably melted material from both the deck beam and latch are melted and intermixed to connect the parts together. A square nut (FIG. 6) or a hexagonal nut (FIG. 5) is preferred for use as latch 32. Rectangular nuts and rhombus nuts (FIGS. 7 & 8, respectively) may also be used, as may any nut with polygon sides and an opening 34 suitable for passage of the hook 30. The flat sides on the nut make it easy to position the flat side of the nut against the flat side of the deck beam 14 and fasten them together. Preferably the deck beam 14 is laid flat with its inner face oriented upward and the nut forming the latch 32 is placed vertically against the deck beam so the parts can be easily welded or otherwise fastened together. Likewise, the deck beam 14 may have its opposing edges vertically oriented and the nut forming the latch 32 may be positioned horizontally against the vertical deck beam 14 so the two parts may be fastened together.

The latch 32 is preferably fastened to the deck beam 34 so that the opening 34 is oriented generally vertically and encircles a generally vertical axis during use. While the latch 32 is generally horizontal during use, it may vary off horizontal in either direction by up to about 45 degrees, and preferably less than about 30 degrees, and more preferably by about 5 degrees. If inclined more than about 45 degrees the possibility that gravity may assist unintended disengagement of the hook 30 from the latch 32 increases greatly. This 45 degree limitation means that the opening 34 faces upward during use, and it also means that the opening 34 and the face of the latch faces the shelf support 20 which is located above the latch. Thus, the face of the washer or threaded nut forming the latch faces the shelf support 20, at a relative angle of 0°-45° with the 0° angle being parallel to the shelf support 20 as shown in the figures. But the latches 32 on opposing deck beams 14 are preferably within 1-5 degrees of each other if a cross-brace 28 having a continuous, solid cross-section is used, otherwise the cross-brace will have to be twisted to bring at least one hook into alignment with the hole 34 in the second-engaged latch 32. A corded cross-brace 28 may accommodate latches orientated on opposing directions as the cord allows the hooks 30 to twist. Thus, the latch 32 preferably has its faces and opening 34 generally parallel to the shelf 18 and shelf support 20 but may be inclined therefrom. As used herein the term generally parallel means a variation of about 10° in either direction.

The latch 32 is located adjacent the bottom edge or lower edge of the deck beam 14. The top surface of the latch 32 is offset from the bottom edge or bottom side of the deck beam 14 by an amount that is preferably slightly larger than the distance between the distal end of the hook 30 and the adjacent side of the cross-member 28. When the lower side of the cross-member 28 abuts the top of the latch 32 (FIG. 3), the hook 30 extends through the latch 32 and preferably extends at least slightly below the latch 32. If the hook extends below the lower edge of the deck beam 14 then items being placed on the shelves 18 may hit the bottom of the hook 30 and urge it out of the latch 32. Thus, the latch 32 is preferably positioned far enough away from the bottom of the deck beam 14 so the latch 32 acts as a limit stop and prevents the distal end of hook 30 from extending below the lower edge or lower side of the deck beam 14. A little more space is preferred to guard against engaging items placed on the shelves that are tipped, and to guard against engaging a user's hands as items are placed on, removed from, or moved on the shelves 18. But to prevent outward splaying of the beam members 14, the latch 14 is preferably at or very near the bottom edge or bottom side of the beam members. Thus the position is a compromise between the effectiveness of the latch and cross-brace 28, and the potential contact of the ends of the hook 32 with items placed on the shelves 18 or with users hands. The position is a further compromise because the outward splaying arises when the shelf 18 is above the cross-brace 28 and the load on the shelf and supporting shelf support 20 cause the deck beams 14 to twist about a longitudinal axis of the each beam. The closer the cross-brace 28 and latches 32 are to the bottom edge or bottom side of the cross-braces, the greater the resisting torque the cross-brace 28 provides. The closer the cross-brace 28 is to the bottom edge or bottom side of the deck beam (i.e., to flange 24), the smaller the cross-sectional area of the cross-brace 28 can be.

For a deck beam 14 having a vertical height of about 3-4 inches during use as in FIGS. 1-3, and a cross-brace 28 formed of metal rod having a diameter of about 0.25 inches and the hook 30 extending about 0.5 inches beyond the bottom side of rod 28, the top of the latch 32 is preferably located about 0.5 to about 1 inch from the bottom of the deck beam 14. If the deck beam has a width W (the vertical height during use), the top of the latch 32 is preferably about 0.2 W to about 0.3 W from the bottom edge of the deck beam.

Depending on the weight to be placed on shelves 18, the number of cross-braces 28 and latches 32 will vary. For most shelves a single cross-brace 28 located at or about the center of the length of the beam member is believed suitable as shown in FIG. 1. For heavier loads on the shelves 18, two equally spaced from the center of the deck beams and thus at locations of about ⅓ and ⅔ the length of the deck beams are believed suitable as shown in FIG. 17. If three cross-braces 28 are used, they would be located at about ¼, ½ and ¾ the length of the deck beams as shown in FIG. 17. Additional cross-members 28 could be used, preferably equally spaced along the length of the opposing deck beams 14.

The internal threads 36 on the annular latch 32 form engaging ridges which provide high friction contact areas that help resist moving the hook 30 out of the opening 34 of the latch 32. That is believed to provide a more secure connection between the hook 30 and latch 32 and thus maintain the hook 30 of the cross-member engaged with the latch 32 and the beam member 14 to which the latch 32 is fastened.

Because the hook 30 passes through the opening 34 of the latch 32, and because the opening 34 must be large enough to allow that passage, threaded fasteners with large openings may be needed. The longer the length of the hook 30, the larger the opening 34. Using standard nuts reduces costs. It is thus advantageous to use thin, commercially available hexagonal nuts and square nuts for the latches 32. Square nuts come with both faces being flat, or one face being flat and the other face curved and it is preferred to use the nut that has both faces flat and parallel. The same applies to hexagonal nuts. Hexagonal Jam nuts are usually thinner than other hex nuts and are preferred for hex nuts. Flanged nuts are not preferred as they are thicker, so flangeless nuts are preferred.

Referring to FIGS. 2 and 4, the opposing ends of the cross-member 28 preferably have the same shaped hook 30. But optionally, as shown in FIG. 4, one end of cross member 28 may have a hooked end 30′ at an acute angle B that is smaller than the acute angle A at the other end, and if so the smaller angled end is preferably installed first. For installation, the cross-member 28 may be angled downward with the more acute angled end 30′ above the latch 32 to pass through the opening 34, with the cross-member 28 being rotated as needed to pass the acute-angled end 30 through the opening 34 and to bring the less-acute angled hook 30 into position above the latch 32 on the opposing deck beam 32, for normal insertion.

Referring to FIGS. 9-11, instead of threaded nuts, it is believed suitable to use washers, preferably rectangular or square washers (FIG. 10) without threads to form the latch 32. The flat sides on the washer are believed suitable for easy fastening of the washer to the deck beam 14 to form the desired latch 32. The washers are also thinner than threaded nuts and that is also desirable. It is also believed suitable to use flat, round washers that have a flat formed on one side of the washer either during manufacture of the washer or afterwards. FIG. 9 shows such a washer. D-shaped washers as in FIG. 11 are made with flat side and are believed suitable. Washers with tapered thickness are also believed suitable as the washers are sufficiently thin that a change in thickness of even 100-200% does not alter their potential use. Tapered washers with one flat side are also believed to be commercially available and suitable for use as latch 32.

While less desirable, it is believed suitable to manufacture the desired washers by stamping them out of metal sheet with the desired flat side and large opening 34 to form latch 32 with a flat edge suitable for easy fastening to the deck beam 14. Alternatively, a commercially available round washer may have a flat side cut or ground by known means to form the latch 32. As desired, the hole in the washer may be enlarged to form a suitable opening 34 for the mating hook 30.

Because standard washers and nuts have circular holes in the center, a larger diameter washer or nut is needed to accommodate the passage of an inclined hook 30. The diameter increases as the length of the hook 30 increases. It is believed possible to deform commercially available, standard nuts by squeezing them from opposing sides to form an elongated hole or opening 34 in the deformed nut, and opening that is not circular but that has a length greater than a width of the opening 34, with the long axis of the opening 34 being perpendicular to a flat side of the nut. If the long axis of the opening 34 is perpendicular to the deck beam 14 then the hook 30 may fit within the opening 34—if the portion of the hook 30 passing through the opening 30 has a circular, oval or similarly elongated shape with any long axis aligned with the long axis of the opening 34 of latch 32. Thus, it is believed suitable to deform standard square nuts (FIG. 6) or rhombus nuts (FIG. 8) or rectangular nuts (FIG. 7) by squeezing opposing sides to deform the original circular opening in the nuts into an elongated opening having a long axis perpendicular to the sides that were not squeezed. It is also believed suitable to squeeze two opposing corners of a hexagonal nut to deform the original circular opening in the hex nuts into an elongated opening having a long axis perpendicular to two opposing, sides. It is further believed suitable to deform opposing flat sides of the nut away from each other to create the elongated opening with a long axis of the opening perpendicular to a straight side of the nut. The elongated opening 34 should be sized and shaped to allow use with the hook 30 of cross-brace 28. An elongated opening 34 may be especially suited to allow use with a hook 30 having a circular cross-sectional shape or an elongated cross-sectional shape at least on the portion passing through the elongated opening of the deformed nut. The nut may be deformed by placing appropriate portions in compression by engaging devices with conforming shapes. The nut may be deformed by placing opposing portions in tension by clamping opposing faces of the nut and pulling the clamped faces in opposing directions, or by placing two pull-bars through the opening 34 of the nut and moving the pull bars in opposing directions away from each other. Deformation by compression is believed to be easier to implement than deformation by tension even though the compressive strength of metal is greater than its tensile strength.

The use of one or more cross-braces 28 provides some advantages not previously appreciated. Normal shelving units 10 for home use have the deck beams 14 and end frame members 16 that are sized to withstand a specified load on the shelf 18 supported by the beams and members 16 supporting that particular shelf. But by making the deck beams 14 and end frame members 16 thinner and compensating for the decreased strength using cross-brace 28 made of a rod having circular cross-section, the shelf load capacity can be maintained while the weight can be reduced. To the extent it was previously known to use cross-braces to increase the load capability of a shelf 18, there are still surprising advantages. Using a rod with a circular cross-sectional shape maximizes the tensile strength while reducing the weight, whether the rod is a solid cross-section or a tubular cross-section. Thus, using a cross-brace 28 formed of a rod having a solid circular cross-section or a tubular circular cross section increases the effectiveness of the cross-brace while reducing weight. Using a cross-brace allows reducing the thickness of the deck beams 14 and end frame members 16 for each shelf. For a conventional sized shelving unit 10 having four rectangular shelves and a corresponding number of eight deck beams 14 and eight end frame members 16 and four posts 12, sufficient to form a shelving unit four feet wide and six feet high and 12 inches deep, the beams 14 and members 16 can be reduced in thickness by 1-2 mm for shelves 18 rated to hold 1,000 pounds per shelf, using cross-braces with solid rods of circular cross-section at the center of each pair of deck beams. The weight of the shelf can be reduced and more shelving units can be shipped. As a specific example, reducing the wall thickness from 1.5 mm to 0.9 mm on the deck beams 14 reduces the weight from 105 pounds to 89 pounds for a 16 pound weight savings for a shelf unit having five shelves. U.S. shipping limits trailers to 44,000 pounds, so that weight savings allows loading 480 units in a 40 foot High Cube container rather than 390 units. That allows more shelves to be shipped.

In addition to the advantageous increase in strength and load capacity provided to the shelves and shelving unit, there is also provided an improved method of manufacturing shelving units and parts. The improved methods include placing a latch having a flat side adjacent a flat surface of deck beam and fastening those parts together by a process using heat or adhesives which form or provide a material 33 joining the latch and deck beam. Processes using heat include welding, soldering, brazing, friction welding and spot welding that heat the material of the deck beam 14 and the latch 32 and any third material (e.g., soldering or brazing), and that preferably melts the material of at least one of the latch and deck beam to bond the melted materials. As used herein, the term “solidified metal” refers to the adhesive joining the deck beam to the nut or washer, the at least partially melted and then solidified metal from one of the deck beam, nut and washer arising from the above described joining operations, or a third material that is melted and bonded to the deck beam, nut or washer while hot.

The latch has formed therein an opening suitable for engaging a hook on a distal end of a cross-brace extending between opposing latches and deck beams. The latch may be formed by using a threaded nut with flat side and a suitable opening and thickness to allow use with the hook and cross-brace. Referring to FIG. 18, the latch 32 may be custom formed by using a threaded nut with flat side and an elongated opening 34 formed by deforming opposing portions of the nut toward each other to create the elongated opening with a long axis of the opening perpendicular to a straight side of the nut, which elongated opening is suitable to allow use with the hook and cross-brace, and which is especially suited to allow use with a hook having a circular cross-sectional shape or an elongated cross-sectional shape at least on the portion passing through the deformed nut. The latch may be custom formed by using a threaded nut with flat sides and an elongated opening formed by deforming opposing portions of the nut away from each other to create the elongated opening with a long axis of the opening perpendicular to a straight side of the nut, which elongated opening is suitable to allow use with the hook and cross-brace, and which is especially suited to allow use with a hook having a circular cross-sectional shape or an elongated cross-sectional shape at least on the portion passing through the deformed nut.

The latch 32 may also be formed by using a flat washer with flat side and a suitable opening and thickness to allow use with the hook and cross-brace. The latch may also be custom formed with a flat side as by punching or cutting the latch from sheets of metal in the form of a washer with a flat side and a hole suitable for use with a hook 30 of cross-brace 28. The latch may also be custom formed by using a commercially available washer with a flat side and pulling opposing sides of that washer apart so as to create an elongated opening with a long axis of the opening perpendicular to a straight side of the washer, which elongated opening is suitable to allow use with the hook 30, and which is especially suited for use with a hook 30 having a circular cross-sectional shape or an elongated cross-sectional shape at least on the portion passing through the deformed washer.

There is also advantageously provided a kit for forming a shelving unit 10. The kit has at least two shelves 18 and four posts 12. For each shelf the kit has two deck beams 14 and two end frame members 16. The posts 12 have a plurality of post openings 22 configured to receive connectors 26 located on the deck beams 14 and end frame members 16. At least the deck beams 14 and optionally the end frame members 16 have a shelf support 20 located to support a shelf 18, preferably in a horizontal plane, but sometimes in a slightly inclined plane to better position items placed on the shelves 18. The deck beams have latches 32 fastened to them adjacent a bottom side of the beams and below the shelves. The latches 32 are preferably formed by using threaded nuts or washers with at least one flat side that are fastened to the deck beams adjacent to the bottom edge or bottom side of the deck beam, at corresponding locations on the deck beams so the latches are directly opposite to each other during use of the deck beams. The kit also includes at least one cross-brace for at least one pair of deck beams, and preferably includes a cross-brace for each pair of deck beams that has directly opposing latches. Additional latches may be provided on the deck beams and advantageously an additional cross-brace is provided for each pair of directly opposing latches during use of the kit. The latches are located at about the center of the deck beams if there is only one latch on each deck beam. The latches are located equally spaced about the center of the deck beams if there are more than two latches for each pair of deck beams.

There is also provided an improved method of assembling shelving units and parts, especially using the parts included in the kits. Four posts 12 are connected to two deck beams 14 and two end frame members 16 (via post openings 22 and connectors 26) to form a generally planar rectangle. A cross-brace 28 is affixed to opposing deck beams 14 by engaging hooks 28 on opposing ends of the cross-brace 28 with a latch 32 on each of the opposing deck beams 14. The latches 32 are located on the deck beams 14 so the latches are directly opposite each other and the cross-brace 28 engaging the latches 32 is perpendicular to the deck beams 14. A shelf 18 is then placed in that rectangular arrangement of the deck beams and end frame members to rest against shelf supports 20 and stabilize the partial assembly. It is preferred that the first shelf and supporting deck beams 14 and end frame members 16 be near the bottom or top end of the posts 12 and shelving unit 10. A second set of deck beams 14, end frame members 16 and a cross member 28 are then then attached to the posts 12 as described above, with the shelf 18 being added thereafter. Successive shelves are attached as described above. \

It is preferable that the second shelf be located at the opposing end of the posts 12, but it could be adjacent the first shelf. It is very desirable that the shelf 18 be placed on the first set of deck beams 14 and end frame members 16 as the rectangular shelf 18 aligns the beams 14 and members 16 to conform to the rectangular shape of the shelf 18. While it is desirable that the shelf 18 be placed on each set of deck beams 14 and end frame members 16 as they are attached to the posts 12, that is optional as the shelves 18 may be placed in position after some or all of the deck beams 14 and end frame members 16 are attached to the posts 18. Similarly, it is desirable to attach the cross-braces 28 to the opposing sets of deck beams 14 before installing further beams and frame members, but that could be delayed and several cross-braces 28 attached at the same time. It is desirable that the cross-braces 28 be installed before the shelves 18 are placed on the deck beams joined by the cross-brace(s) 28 since that makes installation easier. But if the latches 32 are a sufficient distance below the ledge/shelf support 20 to allow a user to install the cross-brace 28 after the shelf is in place, then the cross-braces 28 could be installed after the shelves 18 are resting on the shelf supports 20 of the deck beams 14 joined by the cross-brace(s) 28.

The opposing ends of the cross-member 28 preferably have the same shaped hook 30. But optionally, and referring to FIG. 4, one end may have a hooked end 30′ that has a smaller acute angle B than the acute angle A on other end, and if so the more angled end 30′ is installed first. For installation, the cross-member 28 may be angled downward with the more acute angled end 30′ above the latch 32 to pass through the opening 34, with the cross-member 28 being rotated as needed to pass the acute-angled end 30 through the opening 34 and to bring the less-acute angled hook 30 into position above the latch 32 on the opposing deck beam 32, for normal insertion.

The hook 30 is shown in several figures as a substantially straight end inclined at an acute angle relative to a horizontal plane that is parallel to the shelf 18 above the hook, and inclined at a complementary obtuse angle with respect to the plane of the deck beam 18 where the latch 32 is fastened. The hook 30 need not be straight and preferably has a recurved end portion on it as shown in FIG. 5. The recurved portion makes it easier to engage the edge of the opening 34 in the latch 32 and push the hook 30 through the opening in the latch. The cross-brace 28 is preferably a rod having a circular cross-section or a hollow, tubular cross-section, with the ends bent to form hooks 30. Since the cross-brace 28 is placed in tension to prevent the latches 32 and deck beams 14 from splaying apart, the cross-brace 28 may be a flexible member such as linked members (e.g., a chain) or braided wire cord that can be repeatedly wrapped and unwrapped into compact shapes for compact shipping, with the hooks 30 attached to the ends of the cord or linked members or chain. Metals are preferred for the cross-brace 28 because plastics may creep and gradually increase in length when a constant tension load is applied over time.

As shown in FIGS. 12-15, the latch 32 may be affixed to deck beams 14 of various cross-sectional shapes. The end frame members 16 preferably have the same cross-sectional shape. The end frame members 16 are optional but are preferred. The depicted cross-sectional shapes are open sections, but use of the latch 32 is not limited to such open sections and may be used with various closed sections, such as box sections or stepped sections as in U.S. Pat. No. 2,815,130, the complete contents of which are incorporated herein by reference. The latch 32 may also be used with two open sections mated to form a closed section, as shown in U.S. Pat. No. 4,955,490 and U.S. Published Patent Application 2009007520, the complete contents of which are incorporated herein by reference.

The post openings 22 and the connectors 24 used on the deck beams 14 and end frame members 16 may vary in shape. The openings 22 and connectors 24 may include various shaped fingers or fittings on the ends of one or both of the deck beams 14 and frame members 16 and posts 12. Illustrative connections include those found in U.S. Pat. Nos. 2,815,130, 3,601,432, 4,074,812, the complete contents of which are incorporated herein by reference. The specific type of connection between the posts 12, deck beams 14 and end frame members 16 may thus vary.

Additionally, because the load on the shelves is usually one or a few thousand pounds, and because metal (especially steel) is relative strong and inexpensive, the cross-brace 28 may behave a small cross-sectional diameter even if it is a solid metal rod. But the small diameter makes the cross-brace flexible and that allows a user to install a first hook 30 of the cross-brace by advantageous positioning of the first hook and movement of the cross-brace as described above to engage the first hook with the first latch 32, and then resiliently flexing the thin cross-brace to better align the distal end of the second hook 30 of cross-member 28 with the opening 34 through the latch 32. Thus, the method of assembling the shelves may include the step of resiliently bending the cross-brace 28 to align the distal end of at least one hook 30 with the opening 34 of the latch 32 and facilitating the connection of that hook with that latch. The same applies if the cross-member 28 is a braided cord or linked members such as a chain. As used herein, resiliently bending means bending without exceeding the yield strength of the cross-brace 28 so as to cause a visually perceptible, permanent deformation.

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Thus, the above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including various sectional shapes of the cross-brace 28 and various cross-sectional shapes for the deck beams 14 and end frame members 16. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments. 

What is claimed is:
 1. A deck beam and cross-brace for use with a support frame for a shelf in a shelving assembly, said shelf assembly including a pair of rear posts extending upward and an opposed pair of front posts extending upward with elongated front and rear deck beams extending between and connected to respective pairs of rear posts and front posts in the same plane and parallel to each other to define a support for a shelf, each of the deck beams having an upper side and a lower side, the deck beam and cross-brace comprising: a first deck beam having a first shelf support surface extending along a length of the first deck beam adjacent an upper side of the first deck beam, and a threaded nut or a washer each having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of first deck beam to form a first latch located adjacent the lower side of the first deck beam, the nut or washer being orientated relative to the first deck beam so an opening through the nut or washer faces upward during use; a second deck beam having a second shelf support surface extending along a length of the second deck beam adjacent an upper side of the second deck beam, and a threaded nut or a washer having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of second deck beam to form a second latch located adjacent the lower side of the first deck beam, the nut or washer being orientated relative to the second deck beam so an opening through the nut or washer faces upward during use, the first and second latches located at corresponding locations on their respective deck beams so the first and second latches are directly opposite each other during use; a cross-brace having an elongated body with two opposing ends, each end having a hook extending in the same direction during use, each hook sized to fit through the opening in one of the first or second latches during use, the cross-brace having a length selected so the each hook can pass through the upward facing opening of a different latch during use when the latches are directly opposite each other, and the hooks being configured to pass through the openings during use.
 2. The deck beam and cross-brace of claim 1, wherein melted metal affixes the latch to the deck beam.
 3. The deck beam and cross-brace of claim 2, wherein at least one latch is a threaded nut.
 4. The deck beam and cross-brace of claim 2, wherein at least one latch is a threaded nut and the opening is elongated with a long axis perpendicular to the deck beam at the location of the latch.
 5. The deck beam and cross-brace of claim 2, wherein at least one latch is a square nut.
 6. The deck beam and cross-brace of claim 2, wherein at least one latch is a hexagonal nut.
 7. The deck beam and cross-brace of claim 2, wherein the first latch is generally parallel to the first shelf support and the second latch is generally parallel to the second shelf support.
 8. The deck beam and cross-brace of claim 2, wherein the first latch is inclined at an angle of about 30 degrees or less from an axis perpendicular to the first shelf support.
 9. The deck beam and cross-brace of claim 2, wherein the cross-brace is a rod with a circular cross-section.
 10. The deck beam and cross-brace of claim 2, wherein the cross-brace is one of a braided metal or chain.
 11. The deck beam and cross-brace of claim 2, wherein the cross-brace has one end smaller in cross-section than the other end.
 12. The deck beam and cross-brace of claim 1, wherein an adhesive affixes at least one of the first and second latches to the deck beam and said one of the first and second latches comprises a threaded nut.
 13. The deck beam and cross-brace of claim 1, wherein the first and second latches are located at about the center of a length of the respective deck beams.
 14. The deck beam and cross-brace of claim 2, wherein at least one of the first and second latches is a washer with a flat side.
 15. The deck beam and cross-brace of claim 14, wherein the opening in at least one of the first and second latches is elongated with a long axis perpendicular to the deck beam at the location of the at least one latch.
 16. The cross-brace and latch of claim 14, wherein the first latch is generally parallel to the first shelf support and the second latch is generally parallel to the second shelf support.
 17. The deck beam and cross-brace of claim 14, wherein the first latch is inclined at an angle of about 30° or less from an axis perpendicular to the first shelf support.
 18. The deck beam and cross-brace of claim 14, wherein the cross-brace is a rod with a circular cross-section.
 19. The deck beam and cross-brace of claim 14, wherein the cross-brace is one of a braided metal or chain.
 20. The deck beam and cross-brace of claim 14, wherein the cross-brace has one end smaller in cross-section than the other end.
 21. The deck beam and cross-brace of claim 1, wherein the first and second latches are located at about the center of a length of the respective deck beams.
 22. A kit for a shelving assembly having a pair of rear posts configured to extend upward during use and a pair of front posts configured to extend upward during use, at least one pair of elongated front and rear deck beams configured to extend between and connected to respective pairs of rear posts and front posts in the same plane and parallel to each other to define a support for a shelf during use, the kit comprising: a plurality of first deck beams having a first shelf support surface extending along a length of the respective first deck beam adjacent an upper side of the respective first deck beam, the plurality of first deck beam having a threaded nut or a washer each having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of respective first deck beam to form a first latch located adjacent the lower side of the respective first deck beam, the nut or washer being orientated relative to the respective first deck beam so an opening through the nut or washer faces upward during use; a plurality of second deck beams having a second shelf support surface extending along a length of the respective second deck beam adjacent an upper side of the respective second deck beam, and a threaded nut or a washer having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of respective second deck beam to form a second latch located adjacent the lower side of the respective second deck beam, the nut or washer being orientated relative to the respective second deck beam so an opening through the nut or washer faces upward during use, the first and second latches located at corresponding locations on their respective deck beams so the first and second latches are directly opposite each other during use; a plurality of cross-braces each having an elongated body with two opposing ends, each end having a hook extending in the same direction during use, each hook sized to fit through the opening in one of the first or second, directly opposing latches during use, the cross-braces each having a length selected so the each hook can pass through the upward facing opening of a different latch during use when the latches are directly opposite each other, and the hooks being configured to pass through the openings during use.
 23. A shelving unit having a pair of rear posts extending upward and a pair of front posts extending upward with two pairs of elongated front and rear deck beams extending between and releasably connected to respective pairs of rear posts and front posts in the same plane and parallel to each other to define a support for a shelf during use, the shelf comprising: a first shelf having two opposing first deck beams each having a first shelf support surface extending along a length of the respective first deck beam adjacent an upper side of the respective first deck beam, each of first deck beams having a threaded nut or a washer each with a solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of each respective first deck beam to form a first latch located adjacent the lower side of the respective first deck beam, the first latches being orientated relative to the respective first deck beam so an opening through the nut or washer faces upward, the first latches being directly opposite each other; a plurality of second deck beams having a second shelf support surface extending along a length of the respective second deck beam adjacent an upper side of the respective second deck beam, and a threaded nut or a washer having solidified metal or an adhesive affixing a flat side of the nut or washer to an inward facing surface of respective second deck beam to form a second latch located adjacent the lower side of the respective second deck beam, the nut or washer being orientated relative to the respective second deck beam so an opening through the nut or washer faces upward, the first and second latches located at corresponding locations on their respective deck beams so the first and second latches are directly opposite each other; a first cross-brace having an elongated body with two opposing ends, each end having a hook extending in the same direction, each hook fitting through the opening in a different one of the first latches to help the first deck beams resist splaying under a heavy load; a second shelf and second cross-brace constructed as the first shelf and first cross-brace, but spaced apart therefrom.
 24. The shelving unit of claim 23, wherein the latches comprise threaded fasteners affixed to the deck beams by solidified metal.
 25. A method of making a latch for a deck beam for use with a shelving unit having opposing deck beams each connected to different pairs of posts to form a support for a rectangular shelf, where the latch has an opening extending therethrough which is configured to receive a hook on the end of a cross-brace, the method comprising: placing one of a washer with a flat side or a threaded nut having a flat side against a side of a deck beam, the deck beam having a shelf support extending along an upper side of the deck beam and configured to support a side of a shelf during use, the deck beam having one of a connector or a recess at opposing distal ends of the deck beam to releasably connect the deck beam to a post during use; and positioning the one of the washer or threaded nut adjacent a lower side of the deck beam with a face of the one of the washer or threaded nut facing toward the shelf support; and applying heat or an adhesive to the one of the washer or threaded nut to affix the one of the washer or threaded nut to the deck beam and form a latch for a cross-brace.
 26. The method of claim 28, wherein the positioning step positions a threaded nut generally parallel to the shelf support and the applying step uses heat to melt at least one of the deck beam and the threaded nut.
 27. The method of claim 28, wherein the positioning step positions a washer generally parallel to the shelf support and the applying step uses heat to melt at least one of the deck beam and the threaded nut. 